Project Background
Foton Cummins, a global leader in high-end diesel engine manufacturing, operates one of the world’s most advanced production bases for light, medium, and heavy-duty engines. Facing the growing demand for expanded capacity, the company embarked on building a “l(fā)ights-out factory” — a fully automated, lights-out production facility capable of 24/7 continuous operation.
To achieve this vision, Foton Cummins needed industrial robots with outstanding performance and reliability, as well as collaborative robots that are safe, easy to use, and adaptable for production line upgrades.
As the only domestic company offering mature product lines in both industrial and collaborative robots, ROKAE was chosen as a core strategic partner. With more than 50 models covering payloads from 3 kg to 220 kg, and nearly a decade of deep R&D accumulated across its Beijing, Tokyo, and Shenzhen centers, ROKAE provides robust industrial performance alongside world-leading compliance force-control for collaborative applications.
ROKAE Solution
ROKAE deployed 100+ robots across 30+ application scenarios, delivering tailored automation solutions spanning machining, assembly, surface treatment, inspection, and dispensing. These robots now form the backbone of Foton Cummins’ lights-out factory, covering critical processes from cylinder block machining to final assembly and quality inspection.
Key Applications
· Screw Fastening:
ROKAE xMate CR12 collaborative robots replace manual tightening of cylinder bolts. Without safety fences, they work safely in compact spaces while improving fastening accuracy and quality yield by 15%.
· Precision Assembly:
CR12 collaborative robots with 3D vision ensure precise valve assembly with a pass rate of 99%, enabling safe human-robot collaboration and reducing part damage.
· Flexible Polishing:
CR12 robots with built-in force-control achieve accurate constant-force deburring of engine blocks and heads, eliminating the need for additional sensors and reducing deployment costs.
· Vision Inspection:
Integrated CR12 robots with vision system perform part presence checks, barcode labeling, and appearance inspections with >99% accuracy and 25% faster cycle times, significantly boosting production quality.
· Precision Dispensing:
NB25 series robots equipped with OptiMotion and TrueMotion technologies deliver high-precision, high-speed adhesive dispensing for engine components.
Customer Benefits
By deploying ROKAE’s smart manufacturing solutions, Foton Cummins achieved:
· Labor Optimization: better working environment; 100+ workers freed from repetitive tasks
· Quality Improvement: 6% increase in qualified product rate
· Efficiency Gains: 15% reduction in overall operating costs
· Sustainability: 24/7 lights-out production with enhanced workplace safety
Conclusion
Through its partnership with Foton Cummins, ROKAE has proven its capability to deliver end-to-end intelligent manufacturing solutions that combine flexibility, safety, and reliability. This project not only underscores ROKAE’s leadership in industrial and collaborative robotics but also demonstrates the transformative potential of smart automation in building sustainable, high-efficiency lights-out factories.
Looking ahead, ROKAE will continue to innovate in robotic products and system solutions, empowering more enterprises worldwide to embrace the future of intelligent manufacturing.
